Cleansing compositions

ABSTRACT

Disclosed are cleansing compositions comprising one or more surfactants selected from the group consisting of: i) anionic surfactants, ii) amphoteric surfactants, iii) nonionic surfactants, iv) cationic surfactants and v) mixtures thereof, where the dynamic viscosity of the compositions at 25° C. is at least about 100,000 centipoise and where the cleansing composition results in no or minimal eye sting. Also disclosed disposable articles comprising water insoluble substrates releasably containing the cleansing compositions, a process for making the disposable articles and a method of use.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 11/006,053, filed Dec. 7, 2004 which is a division of U.S.application Ser. No. 10/654,176, filed Sep. 3, 2003 (now abandoned),which is a division of U.S. application Ser. No. 09/725,649, filed Nov.29, 2000, and issued as U.S. Pat. No. 6,677,294 B2 on Jan. 13, 2004.

TECHNICAL FIELD

The present invention relates to cleansing compositions comprising oneor more surfactants selected from the group consisting of: i) anionicsurfactants, ii) amphoteric surfactants, iii) nonionic surfactants, iv)cationic surfactants and v) mixtures thereof, where the dynamicviscosity of the compositions at 25° C. is at least about 100,000centipoise and where the cleansing composition results in no or minimaleye sting.

The instant cleansing compositions are preferably used in releaseablecombination with a disposable substrate as a personal cleansing product.

BACKGROUND OF THE INVENTION

Personal care products, particularly cleansing and conditioningproducts, have traditionally been marketed in a variety of forms such asbar soaps, creams, lotions, and gels. Typically, these products mustsatisfy a number of criteria to be acceptable to consumers. Thesecriteria include cleansing effectiveness, skin feel, mildness to skin,hair, and ocular mucosae, and lather volume. Ideal personal cleansersshould gently cleanse the skin or hair, cause little or no irritation,and should not leave the skin or hair overly dry after frequent use.Further, cleansing compositions, particularly shampoos, designed for usewith children should exhibit mildness to the ocular mucosae, and no orminimal eye sting, should material from the cleansing composition beplaced in the eye.

U.S. Pat. No. 5,139,705 (Wittpenn, Jr., et al.) discloses mildnon-irritating surfactant compositions which include an anionicsurfactant, an amine oxide, a nonionic surfactant having a relativelylow melting point and a nonionic surfactant having a high melting pointrelative to the low melting point nonionic surfactant. The compositionsof Wittpenn, Jr., et al. contain approximately 90% water. The viscosityrequirements of the products of the instant invention would not be metby Wittpenn's compositions.

It is highly desirable to deliver cleansing and conditioning benefitsfrom a disposable substrate. Disposable products are convenient becausethey obviate the need to carry or store cumbersome bottles, bars, jars,tubes, and other forms of clutter associated with cleansing products andother products capable of providing therapeutic or aesthetic benefits.Disposable products are also a more sanitary alternative to the use of asponge, washcloth, or other cleansing implement intended for extensivereuse, because such implements can develop bacterial growth, unpleasantodors, and other undesirable characteristics related to repeated use.

There is also a need for personal care articles, such as disposablewashcloths, which can be easily used by young children. Suchchild-friendly personal care products must be easy to handle and themethod of utilizing them must be easily understood. In addition tomildness to the ocular mucosae, there should be no or minimal eye sting,should material from the cleansing composition contact the eye while achild is using the article. Therefore, the invention encompassesdisposable cleansing articles wherein the cleansing composition producesno or minimal eye sting when introduced into the eye.

Disposable substrates containing mild cleansing compositions producingno or minimal eye sting, would also facilitate such tasks as make-upremoval (particularly eye make-up) and cleaning of animals, such aspets.

While a variety of cleansing compositions associated with substrates areknown in the art, they are not appropriate for use where substantialamounts of cleansing composition can be deposited into the eye. Thepresent invention overcomes these problems by providing a cleansingcomposition which generates no or minimal eye sting.

SUMMARY OF THE INVENTION

The present invention relates to cleansing compositions in paste formcomprising one or more surfactants selected from the group consistingof: i) anionic surfactants, ii) amphoteric surfactants, iii) nonionicsurfactants, iv) cationic surfactants, and v) mixtures thereof, wherethe viscosity of the compositions at 25° C. is at least about 100,000centipoise and where the cleansing composition results in no or minimaleye sting.

One embodiment of the cleansing composition has a first dynamicviscosity at 25° C. and a second dynamic viscosity over a temperaturerange of 60° C. to 125° C., said first and second dynamic viscositieshaving a ratio of said first dynamic viscosity to said second dynamicviscosity greater than or equal to about 1.1.

In addition embodiments of the cleansing composition have a first flowviscosity at 25° C. and a second dynamic viscosity over a temperaturerange of 60° C. to 125° C., said first and second flow viscositieshaving a ratio of said first flow viscosity to said second flowviscosity greater than or equal to about 1.1.

Compositions exhibiting these preferred ratios of viscosities areextremely viscous at room temperature (25° C.) but become liquid atrelatively low temperatures, allowing for ease in processing whilecontributing to stability on the substrate, i.e., the instant cleansingcompositions tend to remain on the substrate due to their viscosity atroom temperature. Cleansing compositions with the above characteristicsare considered “hot melt” surfactant compositions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a plan view of a preferred embodiment of the presentinvention with stripes of cleansing composition and circular bondingpoints.

FIG. 1B is a perspective view of FIG. 1 a.

FIG. 1C is a cross sectional view of FIG. 1A taken along Line 1C.

FIG. 2A is a plan view of a preferred embodiment of the presentinvention with dots of cleansing composition and short bonding lines.

FIG. 2B is an expanded perspective view of FIG. 2 a, showing a crosssection and illustrating the structure of the article.

FIG. 2C is a cross sectional view of FIG. 2A taken along Line 2C.

FIG. 3A is a top plan view of a circular pad of insoluble substrate witha grid of cleansing composition printed on.

FIG. 3B is a perspective view of the circular pad of FIG. 3 a.

FIG. 4 is a perspective view of a mitt with cleansing compositionapplied in the center of the palm.

FIG. 5A is a top plan view showing alternative positions of thecleansing component in relation to a benefit agent in a multiplechambered embodiment of the article of the present invention.

FIG. 5B is a perspective view of the article of FIG. 5 a.

FIG. 5C is a cross sectional view of FIG. 5A taken along Line 5C.

FIG. 6A is a top plan view showing alternative positions of thecleansing component in relation to a benefit agent in a multiplechambered embodiment of the article of the present invention.

FIG. 6B is a perspective view of the article of FIG. 6 a.

FIG. 6C is a cross sectional view of FIG. 6A taken along Line 6C.

DEFINITIONS

All percentages and ratios used herein, unless otherwise indicated, areby weight and all measurements made are at 25° C., unless otherwisedesignated. The invention can comprise, consist of, or consistessentially of, the essential as well as optional ingredients andcompositions described herein.

As used herein the abbreviation “gsm” means “grams per square meter”.

As used herein the abbreviation “cps” means “centipoise per second”.

All documents referred to herein, including patents, patentapplications, and printed publications, are hereby incorporated byreference in their entirety in this disclosure.

As used herein, “disposable” is used in its ordinary sense to mean anarticle that is disposed or discarded after a limited number of usageevents, preferably less than 25, more preferably less than about 10, andmost preferably less than about 2 entire usage events.

As used herein, “substantially dry” means that the articles of thepresent invention exhibit a Moisture Retention Value of less than about0.95 gms, preferably less than about 0.75 gms, even more preferably,less than about 0.5 gms, even more preferably less than about 0.25 gms,even still more preferably less than about 0.15 gms, and mostpreferably, less than about 0.1 gms. The determination of the MoistureRetention Value is discussed hereinafter.

As used herein “paste” or “paste form” means a composition of semisolidconsistency.

Also, as used herein, “non-scouring” means having an Abrasiveness Valueof greater than about 15, preferably greater than about 30, morepreferably greater than about 50, even more preferably greater thanabout 70, and most preferably greater than about 80, as defined by theAbrasiveness Value Methodology described below.

DETAILED DESCRIPTION OF THE INVENTION

The present invention comprises a cleansing composition which comprisesa specific surfactant system as described above. The present inventionalso comprises a cleansing article with comprises said cleansingcomposition releasably disposed on a water insoluble substrate.

In another preferred embodiment of the composition, the anionicsurfactant is preferably an alkyl sulfate. In an even more preferableembodiment, this alkyl sulfate is sodium laureth sulfate. In anadditional preferred embodiment of the composition, the amphotericsurfactant is a betaine. In an even more preferable embodiment, thisbetaine is cocoamidopropyl betaine. In yet another preferred embodimentof the composition, the nonionic surfactant is PEG 200 glyceryltallowate.

An advantage of this invention is that the instant articles are suitablefor use by young children in personal cleansing. Due to the ease andsimple method of use and the fact that usage of the instant thecleansing composition results in low or no eye sting, very youngchildren are able to bathe themselves, to an extent independently, withthe instant articles.

Examples of additional uses of the instant cleansing compositions incombination with disposable substrates are washcloths for make upremoval, specifically eye make up removal and cloths for cleaninganimals, particularly pets.

A. Cleansing Composition

The cleansing composition comprises one or more surfactants selectedfrom the group consisting of: i) anionic surfactants, ii) amphotericsurfactants, iii) nonionic surfactants, iv) cationic surfactants, and v)mixtures thereof, wherein the dynamic viscosity of the composition meetsspecific viscosity specifications outlined above and wherein thecleansing component results in no or minimal eye sting.

The surfactants of the cleansing component may be lathering ornon-lathering surfactants. As used herein, “lathering surfactant” meansa surfactant, which when combined with water and mechanically agitatedgenerates a foam or lather. A “nonlathering surfactant” produces no suchfoam or lather under similar conditions. It is preferred, however, thatthe surfactants be lathering since increased lather is important toconsumers as an indication of cleansing effectiveness.

The surfactants or combinations of surfactants should be mild. As usedherein, “mild” means that the surfactants as well as the articles of thepresent invention demonstrate skin mildness comparable to a mild alkylglyceryl ether sulfonate (AGS) surfactant based synthetic bar, i.e.,synbar. Methods for measuring mildness, or inversely the irritancy, ofsurfactant containing articles, are based on a skin barrier destructiontest. In this test, the milder the surfactant, the lesser the skinbarrier is destroyed. Skin barrier destruction is measured by therelative amount of radio-labeled (tritium labeled) water (3H—H₂O) whichpasses from the test solution through the skin epidermis into thephysiological buffer contained in the diffusate chamber. This test isdescribed by T. J. Franz in the J. Invest. Dermatol., 1975, 64, pp.190-195; and in U.S. Pat. No. 4,673,525, to Small et al., issued Jun.16, 1987, which are both incorporated by reference herein in theirentirety. Other testing methodologies for determining surfactantmildness well known to those skilled in the art can also be used.

A wide variety of lathering surfactants are useful herein and includethose selected from the group consisting of anionic latheringsurfactants, nonionic lathering surfactants, amphoteric latheringsurfactants, and mixtures thereof.

Anionic Lathering Surfactants

Nonlimiting examples of anionic lathering surfactants useful in thecompositions of the present invention are disclosed in McCutcheon's,Detergents and Emulsifiers, North American edition (1986), published byAllured Publishing Corporation; McCutcheon's, Functional Materials,North American Edition (1992); and U.S. Pat. No. 3,929,678, to Laughlinet al., issued Dec. 30, 1975, each of which is incorporated by referenceherein in their entirety.

A wide variety of anionic surfactants are potentially useful herein.Nonlimiting examples of anionic lathering surfactants include thoseselected from the group consisting of alkyl sulfates and alkyl ethersulfates, sulfated monoglycerides, sulfonated olefins, alkyl arylsulfonates, primary or secondary alkane sulfonates, alkylsulfosuccinates, acyl taurates, acyl isethionates, alkyl glycerylethersulfonates, alkyl glyceryl sulfonates, alkyl glyceryl esters, alkylglycinates, sulfonated methyl esters, sulfonated fatty acids, alkylphosphates, acyl glutamates, acyl sarcosinates, alkyl sulfoacetates,acylated peptides, alkyl ether carboxylates, acyl lactylates, anionicfluorosurfactants, amid ether sulfates, and combinations thereof.Combinations of anionic surfactants can be used effectively in thepresent invention.

Preferred anionic surfactants for use in the cleansing component includealkyl and alkyl ether sulfates. These materials have the respectiveformulae R¹O—SO₃M and R¹(CH₂H₄O)x-O—SO₃M, wherein R¹ is a saturated orunsaturated, branched or unbranched alkyl group from about 8 to about 24carbon atoms, x is 1 to 10, and M is a water-soluble cation such asammonium, sodium, potassium, magnesium, triethanolamine (TEA),diethanolamine (DEA) and monoethanolamine(MEA). The alkyl sulfates aretypically made by the sulfation product of monohydric alcohols (havingfrom about 8 to about 24 carbon atoms) using sulfur trioxide or otherknown sulfation techniques. The alkyl ether sulfates are typically madeby sulfation of condensation products of ethylene oxide and monohydricalcohols (having from about 8 to about 24 carbon atoms). These alcoholscan be derived from fats, e.g., coconut oil or tallow, or can besynthetic. Specific examples of alkyl sulfates which may be used in thecleansing component are sodium, ammonium, potassium, magnesium, and TEAsalts of lauryl or myristyl sulfate. Examples of alkyl ether sulfateswhich may be used include ammonium, sodium, magnesium, or TEA laureth-3sulfate.

Another suitable class of anionic surfactants are the sulfatedmonoglycerides of the form R¹CO—O—CH₂—C(OH)H—CH₂—O—SO₃M, wherein R¹ is asaturated or unsaturated, branched or unbranched alkyl group from about8 to about 24 carbon atoms, and M is a water-soluble cation such asammonium, sodium, potassium, magnesium, triethanolamine, diethanolamineand monoethanolamine. These are typically made by the reaction ofglycerin with fatty acids (having from about 8 to about 24 carbon atoms)to form a monoglyceride and the subsequent sulfation of thismonoglyceride with sulfur trioxide. An example of a sulfatedmonoglyceride is sodium cocomonoglyceride sulfate.

Other suitable anionic surfactants include olefin sulfonates of the formR¹SO₃M, wherein R¹ is a mono-olefin having from about 12 to about 24carbon atoms, and M is a water-soluble cation such as ammonium, sodium,potassium, magnesium, triethanolamine, diethanolamine andmonoethanolamine. These compounds can be produced by the sulfonation ofalpha olefins by means of uncomplexed sulfur trioxide, followed byneutralization of the acid reaction mixture in conditions such that anysultones which have been formed in the reaction are hydrolyzed to givethe corresponding hydroxyalkanesulfonate. An example of a sulfonatedolefin is sodium C14/C16 alpha olefin sulfonate.

Other suitable anionic surfactants are the linear alkylbenzenesulfonates of the form R¹—C₆H₄—SO₃M, wherein R¹ is a saturated orunsaturated, branched or unbranched alkyl group from about 8 to about 24carbon atoms, and M is a water-soluble cation such as ammonium, sodium,potassium, magnesium, triethanolamine, diethanolamine andmonoethanolamine. These are formed by the sulfonation of linear alkylbenzene with sulfur trioxide. An example of this anionic surfactant issodium dodecylbenzene sulfonate.

Still other anionic surfactants suitable for this cleansing componentinclude the primary or secondary alkane sulfonates of the form R¹SO₃M,wherein R¹ is a saturated or unsaturated, branched or unbranched alkylchain from about 8 to about 24 carbon atoms, and M is a water-solublecation such as ammonium, sodium, potassium, magnesium, triethanolamine,diethanolamine and monoethanolamine. These are commonly formed by thesulfonation of paraffins using sulfur dioxide in the presence ofchlorine and ultraviolet light or another known sulfonation method. Thesulfonation can occur in either the secondary or primary positions ofthe alkyl chain. An example of an alkane sulfonate useful herein isalkali metal or ammonium C13-C17 paraffin sulfonates.

Still other suitable anionic surfactants are the alkyl sulfosuccinates,which include disodium N-octadecylsulfosuccinamate; diammonium laurylsulfosuccinate; tetrasodiumN-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinate; diamyl ester of sodiumsulfosuccinic acid; dihexyl ester of sodium sulfosuccinic acid; anddioctyl esters of sodium sulfosuccinic acid.

Also useful are taurates which are based on taurine, which is also knownas 2-aminoethanesulfonic acid. Examples of taurates includeN-alkyltaurines such as the one prepared by reacting dodecylamine withsodium isethionate as detailed in U.S. Pat. No. 2,658,072 which isincorporated herein by reference in its entirety. Other examples basedof taurine include the acyl taurines formed by the reaction of n-methyltaurine with fatty acids (having from about 8 to about 24 carbon atoms).

Another class of anionic surfactants suitable for use in the cleansingcomponent is the acyl isethionates. The acyl isethionates typically havethe formula R¹CO—O—CH₂CH₂SO₃M wherein R¹ is a saturated or unsaturated,branched or unbranched alkyl group having from about 10 to about 30carbon atoms, and M is a cation. These are typically formed by thereaction of fatty acids (having from about 8 to about 30 carbon atoms)with an alkali metal isethionate. Nonlimiting examples of these acylisethionates include ammonium cocoyl isethionate, sodium cocoylisethionate, sodium lauroyl isethionate, and mixtures thereof.

Still other suitable anionic surfactants are the alkylglyceryl ethersulfonates of the form R¹—OCH₂—C(OH)H—CH₂—SO₃M, wherein R¹ is asaturated or unsaturated, branched or unbranched alkyl group from about8 to about 24 carbon atoms, and M is a water-soluble cation such asammonium, sodium, potassium, magnesium, triethanolamine, diethanolamineand monoethanolamine. These can be formed by the reaction ofepichlorohydrin and sodium bisulfite with fatty alcohols (having fromabout 8 to about 24 carbon atoms) or other known methods. One example issodium cocoglyceryl ether sulfonate.

Other suitable anionic surfactants include the sulfonated fatty acids ofthe form R¹—CH(SO₄)—COOH and sulfonated methyl esters of the formR¹—CH(SO₄)—CO—O—CH₃, where R¹ is a saturated or unsaturated, branched orunbranched alkyl group from about 8 to about 24 carbon atoms. These canbe formed by the sulfonation of fatty acids or alkyl methyl esters(having from about 8 to about 24 carbon atoms) with sulfur trioxide orby another known sulfonation technique. Examples include alphasulphonated coconut fatty acid and lauryl methyl ester.

Other anionic materials include phosphates such as monoalkyl, dialkyl,and trialkylphosphate salts formed by the reaction of phosphorouspentoxide with monohydric branched or unbranched alcohols having fromabout 8 to about 24 carbon atoms. These can also be formed by otherknown phosphation methods. An example from this class of surfactants issodium mono or dilaurylphosphate.

Other anionic materials include acyl glutamates corresponding to theformula R¹CO—N(COOH)—CH₂CH₂—CO₂M wherein R¹ is a saturated orunsaturated, branched or unbranched alkyl or alkenyl group of about 8 toabout 24 carbon atoms, and M is a water-soluble cation. Nonlimitingexamples of which include sodium lauroyl glutamate and sodium cocoylglutamate.

Other anionic materials include alkanoyl sarcosinates corresponding tothe formula R¹CON(CH₃)—CH₂CH₂—CO₂M wherein R¹ is a saturated orunsaturated, branched or unbranched alkyl or alkenyl group of about 10to about 20 carbon atoms, and M is a water-soluble cation. Nonlimitingexamples of which include sodium lauroyl sarcosinate, sodium cocoylsarcosinate, and ammonium lauroyl sarcosinate.

Other anionic materials include alkyl ether carboxylates correspondingto the formula R¹—(OCH₂CH₂)x-OCH₂—CO₂M wherein R¹ is a saturated orunsaturated, branched or unbranched alkyl or alkenyl group of about 8 toabout 24 carbon atoms, x is 1 to 10, and M is a water-soluble cation.Nonlimiting examples of which include sodium laureth carboxylate. Otheranionic materials include acyl lactylates corresponding to the formulaR₁CO—[O—CH(CH₃)—CO]x-CO₂M wherein R¹ is a saturated or unsaturated,branched or unbranched alkyl or alkenyl group of about 8 to about 24carbon atoms, x is 3, and M is a water-soluble cation. Nonlimitingexamples of which include sodium cocoyl lactylate.

Other anionic materials include the carboxylates, nonlimiting examplesof which include sodium lauroyl carboxylate, sodium cocoyl carboxylate,and ammonium lauroyl carboxylate. Anionic flourosurfactants can also beused.

Other anionic materials include natural soaps derived from thesaponification of vegetable and/or animal fats & oils examples of whichinclude sodium laurate, sodium myristate, TEA palmitate, potassiumstearate, sodium tallowate, and sodium cocoate.

Any counter cation, M, can be used on the anionic surfactant.Preferably, the counter cation is selected from the group consisting ofsodium, potassium, ammonium, monoethanolamine, diethanolamine, andtriethanolamine. More preferably, the counter cation is ammonium.

Nonionic Lathering Surfactants

Nonlimiting examples of nonionic lathering surfactants for use in thecompositions of the present invention are disclosed in McCutcheon's,Detergents and Emulsifiers, North American edition (1986), published byallured Publishing Corporation; and McCutcheon's, Functional Materials,North American Edition (1992); both of which are incorporated byreference herein in their entirety.

Nonionic lathering surfactants useful herein include those selected fromthe group consisting of alkyl glucosides, alkyl polyglucosides,polyhydroxy fatty acid amides, alkoxylated fatty alcohols, alkoxylatedfatty acid esters, sucrose esters, and mixtures thereof.

Alkyl glucosides and alkyl polyglucosides are useful herein, and can bebroadly defined as condensation products of long chain alcohols, e.g.,about C₈₋₃₀ alcohols, with sugars or starches or sugar or starchpolymers, i.e., glycosides or polyglycosides. These compounds can berepresented by the formula (Su)_(n)-O—R wherein Su is a sugar moietysuch as glucose, fructose, mannose, and galactose; n is an integer offrom about 1 to about 1000, and R is an about C₈₋₃₀ alkyl group.Examples of long chain alcohols from which the alkyl group can bederived include decyl alcohol, cetyl alcohol, stearyl alcohol, laurylalcohol, myristyl alcohol, oleyl alcohol, and the like. Preferredexamples of these surfactants include those wherein Su is a glucosemoiety, R is an about C8-20 alkyl group, and n is an integer of fromabout 1 to about 9. Commercially available examples of these surfactantsinclude decyl polyglucoside (available as APG 325 CS from Henkel) andlauryl polyglucoside (available as APG 600CS and 625 CS from Henkel).Also useful are sucrose ester surfactants such as sucrose cocoate andsucrose laurate.

Other useful nonionic surfactants include polyhydroxy fatty acid amidesurfactants, more specific examples of which include glucosamides,corresponding to the structural formula:

wherein: R¹ is H, C₁-C₄ alkyl, 2-hydroxyethyl, 2-hydroxy-propyl,preferably about C₁-C₄ alkyl, more preferably methyl or ethyl, mostpreferably methyl; R² is C₅-C₃₁ alkyl or alkenyl, preferably aboutC₇-C₁₉ alkyl or alkenyl, more preferably about C₉-C₁₇ alkyl or alkenyl,most preferably about C₁₁-C₁₅ alkyl or alkenyl; and Z is apolhydroxyhydrocarbyl moiety having a linear hydrocarbyl chain with aleast 3 hydroxyls directly connected to the chain, or an alkoxylatedderivative (preferably ethoxylated or propoxylated) thereof. Zpreferably is a sugar moiety selected from the group consisting ofglucose, fructose, maltose, lactose, galactose, mannose, xylose, andmixtures thereof. An especially preferred surfactant corresponding tothe above structure is coconut alkyl N-methyl glucoside amide (i.e.,wherein the R²CO— moiety is derived from coconut oil fatty acids).Processes for making compositions containing polyhydroxy fatty acidamides are disclosed, for example, in G.B. Patent Specification 809,060,published Feb. 18, 1959, by Thomas Hedley & Co., Ltd.; U.S. Pat. No.2,965,576, to E. R. Wilson, issued Dec. 20, 1960; U.S. Pat. No.2,703,798, to A. M. Schwartz, issued Mar. 8, 1955; and U.S. Pat. No.1,985,424, to Piggott, issued Dec. 25, 1934; each of which areincorporated herein by reference in their entirety.

Other examples of nonionic surfactants include amine oxides. Amineoxides correspond to the general formula R1R₂R₃N→O, wherein R₁ containsan alkyl, alkenyl or monohydroxy alkyl radical of from about 8 to about18 carbon atoms, from 0 to about 10 ethylene oxide moieties, and from 0to about 1 glyceryl moiety, and R₂ and R₃ contain from about 1 to about3 carbon atoms and from 0 to about 1 hydroxy group, e.g., methyl, ethyl,propyl, hydroxyethyl, or hydroxypropyl radicals. The arrow in theformula is a conventional representation of a semipolar bond. Examplesof amine oxides suitable for use in this invention includedimethyl-dodecylamine oxide, oleyldi(2-hydroxyethyl) amine oxide,dimethyloctylamine oxide, dimethyl-decylamine oxide,dimethyl-tetradecylamine oxide, 3,6,9-trioxaheptadecyldiethylamineoxide, di(2-hydroxyethyl)-tetradecylamine oxide,2-dodecoxyethyldimethylamine oxide,3-dodecoxy-2-hydroxypropyldi(3-hydroxypropyl)amine oxide,dimethylhexadecylamine oxide.

Nonlimiting examples of preferred nonionic surfactants for use hereinare those selected from the group consisting of about C₈-C₁₄ glucoseamides, about C₈-C₁₄ alkyl polyglucosides, sucrose cocoate, sucroselaurate, and mixtures thereof.

Amphoteric Lathering Surfactants

The term “amphoteric lathering surfactant,” as used herein, is alsointended to encompass zwitterionic surfactants, which are well known toformulators skilled in the art as a subset of amphoteric surfactants.

A wide variety of amphoteric lathering surfactants can be used in thecompositions of the present invention. Particularly useful are thosewhich are broadly described as derivatives of aliphatic secondary andtertiary amines, preferably wherein the nitrogen is in a cationic state,in which the aliphatic radicals can be straight or branched chain andwherein one of the radicals contains an ionizable water solubilizinggroup, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate.

Nonlimiting examples of amphoteric surfactants useful in thecompositions of the present invention are disclosed in McCutcheon's,Detergents and Emulsifiers, North American edition (1986), published byallured Publishing Corporation; and McCutcheon's, Functional Materials,North American Edition (1992); both of which are incorporated byreference herein in their entirety.

Nonlimiting examples of amphoteric or zwitterionic surfactants are thoseselected from the group consisting of betaines, sultaines,hydroxysultaines, alkyliminoacetates, iminodialkanoates, aminoalkanoatesalkylammonium propionates, and mixtures thereof.

Examples of betaines include the higher alkyl betaines, such as cocodimethyl carboxymethyl betaine, lauryl dimethyl carboxymethyl betaine,lauryl dimethyl alpha-carboxyethyl betaine, cetyl dimethyl carboxymethylbetaine, cetyl dimethyl betaine (available as Lonzaine 16SP from LonzaCorp.), lauryl bis-(2-hydroxyethyl) carboxymethyl betaine, oleyldimethyl gamma-carboxypropyl betaine, laurylbis-(2-hydroxypropyl)alpha-carboxyethyl betaine, coco dimethylsulfopropyl betaine, lauryl dimethyl sulfoethyl betaine, laurylbis-(2-hydroxyethyl) sulfopropyl betaine, amidobetaines andamidosulfobetaines (wherein the RCONH(CH₂)₃ radical is attached to thenitrogen atom of the betaine), oleyl betaine (available as amphotericVelvetex OLB-50 from Henkel), and cocamidopropyl betaine (available asVelvetex BK-35 and BA-35 from Henkel).

Examples of sultaines and hydroxysultaines include materials such ascocamidopropyl hydroxysultaine (available as Mirataine CBS fromRhone-Poulenc).

Preferred for use herein are amphoteric surfactants having the followingstructure:

wherein R¹ is unsubstituted, saturated or unsaturated, straight orbranched chain alkyl having from about 9 to about 22 carbon atoms.Preferred R¹ has from about 11 to about 18 carbon atoms; more preferablyfrom about 12 to about 18 carbon atoms; more preferably still from about14 to about 18 carbon atoms; m is an integer from 1 to about 3, morepreferably from about 2 to about 3, and more preferably about 3; n iseither 0 or 1, preferably 1; R² and R³ are independently selected fromthe group consisting of alkyl having from 1 to about 3 carbon atoms,unsubstituted or mono-substituted with hydroxy, preferred R² and R³ areCH₃; X is selected from the group consisting of CO₂, SO₃ and SO₄; R⁴ isselected from the group consisting of saturated or unsaturated, straightor branched chain alkyl, unsubstituted or monosubstituted with hydroxy,having from 1 to about 5 carbon atoms. When X is CO₂, R⁴ preferably has1 or 3 carbon atoms, more preferably 1 carbon atom. When X is SO₃ orSO₄, R⁴ preferably has from about 2 to about 4 carbon atoms, morepreferably 3 carbon atoms.

Examples of amphoteric surfactants of the present invention include thefollowing compounds:

-   Cetyl dimethyl betaine (this material also has the CTFA designation    cetyl betaine)-   Cocamidopropylbetaine    wherein R has from about 9 to about 13 carbon atoms

Cocamidopropyl hydroxy sultaine

wherein R has from about 9 to about 13 carbon atoms, Examples of otheruseful amphoteric surfactants are alkyliminoacetates, andiminodialkanoates and aminoalkanoates of the formulas RN[CH₂)_(m)CO₂M]₂and RNH(CH₂)_(m)CO₂M wherein m is from about 1 to 4, R is An aboutC₈-C₂₂ alkyl or alkenyl, and M is H, alkali metal, alkaline earth metalammonium, or an alkanolammonium. Also included are imidazolinium andammonium derivatives. Specific examples of suitable amphotericsurfactants include sodium 3-dodecyl-aminopropionate, sodium3-dodecylaminopropane sulfonate, N-higher alkyl aspartic acids such asthose produced according to the teaching of U.S. Pat. No. 2,438,091which is incorporated herein by reference in its entirety; and theproducts sold under the trade name “Miranol” and described in U.S. Pat.No. 2,528,378, which is incorporated herein by reference in itsentirety. Other examples of useful amphoterics include amphotericphosphates, such as coamidopropyl PG-dimonium chloride phosphate(commercially available as Monaquat PTC, from Mona Corp.). Also usefulare amphoacetates such as disodium lauroamphodiacetate, sodiumlauroamphoacetate, and mixtures thereof.

Preferred lathering surfactants are selected from the group consistingof anionic lathering surfactants selected from the group consisting ofammonium lauroyl sarcosinate, sodium trideceth sulfate, sodium lauroylsarcosinate, ammonium laureth sulfate, sodium laureth sulfate, ammoniumlauryl sulfate, sodium lauryl sulfate, ammonium cocoyl isethionate,sodium cocoyl isethionate, sodium lauroyl isethionate, sodium cetylsulfate, sodium monolauryl phospate, sodium cocoglyceryl ethersulfonate, sodium C₉-C₂₂ soap, and combinations thereof; nonioniclathering surfactants selected from the group consisting of lauramineoxide, cocoamine oxide, decyl polyglucose, lauryl polyglucose, sucrosecocoate, C₁₂₋₁₄ glucosamides, sucrose laurate, and combinations thereof;cationic lathering surfactants selected from the group consisting offatty amines, di-fatty quaternary amines, tri-fatty quaternary amines,imidazolinium quaternary amines, and combinations thereof; amphotericlathering surfactants selected from the group consisting of disodiumlauroamphodiacetate, sodium lauroamphoacetate, cetyl dimethyl betaine,cocoamidopropyl betaine, cocoamidopropyl hydroxy sultaine, andcombinations thereof.

Cationic Lathering Surfactants

Cationic lathering surfactants are also useful in the articles of thepresent invention. Suitable cationic lathering surfactants include, butare not limited to, fatty amines, di-fatty quaternary amines, tri-fattyquaternary amines, imidazolinium quaternary amines, and combinationsthereof. Suitable fatty amines include monalkyl quaternary amines suchas cetyltrimethylammonium bromide. A suitable quaternary amine isdialklamidoethyl hydroxyethylmonium methosulfate. The fatty amines,however, are preferred. It is preferred that a lather booster is usedwhen the cationic lathering surfactant is the primary latheringsurfactant of the cleansing component. Additionally, nonionicsurfactants have been found to be particularly useful in combinationwith such cationic lathering surfactants.

B. Viscosity/Temperature Relationship of Cleansing Compositions

As disclosed above, the cleansing compositions of the instant inventionare, preferably, “hot melt” surfactant systems. Hot melt surfactantsystems have high viscosity at or around room temperature, and then melt(become substantially liquid) at higher temperatures. Such systems areadvantageous during processing of a disposable, substantially dry (ordry to the touch) cleansing article since the surfactant system can beapplied (e.g., coated, sprayed, extruded) to the substrate at a lowviscosity (e.g., a liquid) at higher than room temperature, and then asthe system cools down, it becomes a high viscosity paste or solid. Inthe present invention there is a required range of temperatures andviscosities at which these changes take place.

Unless otherwise noted, all viscosities are measured as dynamicviscosities, as described herein.

Another consideration is stability of the finished product. Thecleansing composition must maintain a certain viscosity at or aroundroom temperature (25° C.) so that when the product is stored, the systemstays stable on the substrate (and does not melt off). This lowerviscosity limit is at least 100,000 cps for the present invention. Theviscosity at higher temperatures is preferably less than 100 million cpsin order to keep the system easy to process.

There is also a temperature range at which the cleansing compositionundergoes significant changes in viscosity. The instant cleansingcompositions are highly viscous at room temperature and melt into liquidform at a temperature below 125° C. The temperature at which thecomposition melts should not be too low in order to prevent thecleansing composition, which has been deposited on the substrate frombecoming unstable (i.e., likely to melt) during normal usage conditions(room temperature up to ˜25° C.), but should not be too high or thetemperature necessary in order to apply the cleansing composition to thesubstrate will degrade the surfactants and any perfume that may bepresent (>125° C.). Therefore, for the present invention, it ispreferred that the significant viscosity change occurs at a temperaturewithin the range of about 25° C. to about 125° C., preferably within therange of about 40° C. to about 70° C., and most preferably within therange of about 40° C. to about 60° C.

Due to these constraints, there is a requirement of the aforementionedsignificant viscosity change that the ratio of the dynamic viscositiesof the cleansing composition are such that the cleansing composition hasa first dynamic viscosity at 25° C. and a second dynamic viscosity at T°C. (as defined above), the first and second dynamic viscosities having aratio of the first dynamic viscosity to the second dynamic viscosity ofgreater than or equal to 1.1, more preferably greater than or equal to5, even more preferably greater than or equal to 8, and most preferably,greater than or equal to 10. This requirement ensures that the viscositychange is significant enough to allow a process advantage.

Additionally, the flow viscosities preferably have a similar ratio atthe same temperatures.

C. Water Insoluble Substrate/Article

In a preferred embodiment, the present invention is an articlecomprising a water insoluble substrate with the cleansing compositiondescribed above deposited thereon. The water insoluble substratecomprises at least one layer, a first substrate sheet to which theinstant paste form cleansing composition is applied. In a preferredembodiment there is at least a second substrate sheet which is joined tothe first layer and which overlays the cleansing composition.

The Figures illustrate preferred embodiments of the present invention.

Top plan view FIG. 1A shows stripes 1 of cleansing composition (locationonly, not visible in actual article), bonding sites 2 multiple, andsecond substrate sheet 3, which comprises a finished article (10).

Perspective view FIG. 1B (of the embodiment shown in FIG. 1A) showsfirst substrate sheet 5 with stripes 1 of cleansing composition thereonand covered with second substrate sheet 3, third substrate sheet 4, andbonded at sites 2 multiple.

FIG. 1C is a cross sectional view, taken along line 1C of FIG. 1A,showing first substrate sheet 5, bonding sites 2, second substrate sheet3, with stripes of cleansing composition 1 deposited thereon and thirdsubstrate sheet 4.

Top plan view FIG. 2A shows the location of dots of cleansingcomposition 21 (indicated on second substrate sheet 23 in dashed linesas the deposit of the dots is not actually visible in the top planview), bonded at sites multiple 22 which comprises a finished article(20).

Perspective view FIG. 2B taken along line 2C of FIG. 2A, shows thelocation of dots of cleansing composition 21 (indicated on secondsubstrate sheet 23 in dashed lines as the deposit of the dots is notactually visible in the top plan view), bonded at sites multiple 22,third substrate sheet 24, first substrate sheet 25, and fourth substratesheet 26 which comprises a finished article.

Cross sectional view FIG. 2C taken along line 2C of FIG. 2A, shows dotsof cleansing composition 21, bonded at sites multiple 22, secondsubstrate sheet 23, third substrate sheet 24, first substrate sheet 25,and fourth substrate sheet 26.

Top plan view FIG. 3A shows lines 31 of cleansing composition depositedin the form of a grid onto a substrate sheet 32 which comprises afinished article (30).

Perspective view FIG. 3B of the embodiment of FIG. 3A, shows lines 31 ofcleansing composition deposited in the form of a grid onto a substratesheet 32.

FIG. 4 shows an article in the form of a mitt of substrate sheet 42 withcleansing composition 1 deposited in the area of the palm whichcomprises a finished article (40).

Top plan view FIG. 5A shows stripes 51 of cleansing composition, stripes56 of benefit agent (neither of these stripes is visible in the actualarticle as they are deposited onto the middle layer), bonding sites 52multiple and second substrate sheet 53 which comprises a finishedarticle (50).

Perspective view FIG. 5B of the embodiment of FIG. 5A, shows secondsubstrate sheet 53 and first substrate sheet 55 with stripes 51 ofcleansing composition and stripes of benefit agent 56 therein, bondingsites 52 multiple, and third substrate sheet 54.

Cross sectional view FIG. 5C taken along line 5C of FIG. 5A, showsstripes 51 of cleansing composition, stripes 56 of benefit agent,bonding sites, multiple 52, second substrate sheet 53, third substratesheet 54, first substrate sheet 55.

Top plan view FIG. 6A shows stripes 61 of cleansing composition, bondingsites, multiple 62 with embedded benefit agent and second substratesheet 63 which comprises a finished article (60).

Perspective view FIG. 6B of the embodiment of FIG. 6A, shows firstsubstrate sheet 65 with stripes 61 of cleansing composition thereon,second substrate sheet 63, third substrate sheet 64, and bonded at sites62, multiple with embedded benefit agent.

Cross sectional view FIG. 6C taken along line 6C of FIG. 6A, showsstripes of cleansing composition (61), bonded at sites (62), multiple,first substrate sheet (65), second substrate sheet (63), third substratesheet (64), and benefit agent embedded at bonding sites (67) whichcomprises a finished article (60).

When the cleansing composition is disposed on the water insolublesubstrate, the articles of the present invention comprise from about0.5% to about 3,000%, preferably from about 50% to about 2,000%, andmore preferably from about 100% to about 1,500%, based on the weight ofthe untreated water insoluble substrate, of the surfactant composition.Also, for personal cleansing purposes a preferred article of the presentinvention preferably comprises at least about 1 gram, by weight of thetreated water insoluble substrate, of a surfactant.

Preferably, the substrate sheets are soft to the skin of the consumerwhen used. In any case, however, the first sheet and the second sheetare each defined as having both an interior and an exterior surface. Inboth cases, the interior surfaces of the sheets are those which face theinside or innermost portion of the article of the present inventionwhereas the exterior surfaces of the sheets are those which face theoutside or outermost portion of the article.

In yet another preferred embodiment, the article of the presentinvention comprises one or more additional sheets which one havingordinary skill in the art would recognize as separate and distinct fromthe first and second sheets yet which are attached to the first andsecond sheets at some point. The additional sheets are suitable forenhancing the overall grippability of the side of the article closest tothe hand or other means for exerting mechanical action on the surface tobe cleansed. Also, the additional sheets may be suitable for enhancingeither the soft feel or scrubbing efficacy of the side of the articlewhich contacts the area to be cleansed. In any instance, theseadditional sheets may also be referred to as consecutively numberedsheets in addition to the two essential sheets of the articles of thepresent invention, e.g., third sheet, fourth sheet, etc.

In a preferred embodiment, at least one additional sheet is positionedadjacently to the exterior surface of the first sheet such that it formsthe outermost portion of the article. In this capacity, the third sheetis useful for providing a surface suitable for facilitated gripping ofthe article by the hand. It is therefore desirable that when theadditional sheet is positioned adjacently to the exterior surface of thefirst layer, the third sheet exhibits a higher wet friction coefficientrelative to the other sheets of the article.

In another embodiment, the article comprises a fourth sheet which isdisposed adjacent to the second sheet wherein the fourth sheet comprisesthe same as or different materials from the third sheet.

Suitable materials for use as sheets of the water insoluble substrateare selected from the group consisting of, but not limited to,nonwovens, wovens, sponges, polymeric netted meshes, formed films,battings, and combinations thereof. In preferred embodiments, theadditional sheets may be composite materials such that they each consistof one or more plies, each ply being made from the same or differentmaterials than the other plies.

In a preferred embodiment, the additional sheets of the articles of thepresent invention have a thickness of at least one millimeter. In thispreferred embodiment, the additional sheets having a thickness of atleast one millimeter provide structural support for the article suchthat its original shape is maintained throughout its useful life and thesheet also tends to enhance the softness perception to the consumer.

Materials suitable for use as the sheets of the water insolublesubstrate having a thickness of at least one millimeter include, but arenot limited to, those web materials disclosed in U.S. Pat. No.5,518,801, issued to Chappell et al. on May 21, 1996, which isincorporated by reference herein in its entirety.

Additional materials that are suitable for use as the sheets of thewater insoluble substrate of the present invention include thecellulosic nonwovens described in U.S. Pat. No. 4,447,294, the formedfilms of U.S. Pat. Nos. 4,342,314 and 4,629,643.

Furthermore, each of the sheets of the water insoluble substrate of thepresent invention may be made into a wide variety of shapes and formsincluding flat pads, thick pads, thin sheets, ball-shaped implements,irregularly shaped implements. The exact size of the sheets will dependupon the desired use and characteristics of the article and may range insurface area size from about a square inch to about hundreds of squareinches. Especially convenient layer and article shapes include, but arenot limited to, square, circular, rectangular, hourglass, or oval shapeshaving a surface area of from about 5 in² to about 200 in², preferablyfrom about 6 in² to about 120 in², and more preferably from about 15 in²to about 100 in², and a thickness of from about 0.5 mm to about 50 mm,preferably from about 1 mm to about 25 mm, and more preferably fromabout 2 mm to about 20 mm.

D. Optional Components

The cleansing compositions and/or articles of the present invention maycontain a variety of other components such as are conventionally used ina given product type provided that they do not unacceptably alter thebenefits of the invention. These optional components should be suitablefor application to human skin and hair; that is, when incorporated intothe article they are suitable for use in contact with human skin withoutundue toxicity, incompatibility, instability, allergic response, and thelike, within the scope of sound medical or formulator's judgment. TheCTFA Cosmetic Ingredient Handbook, Second Edition (1992) describes awide variety of nonlimiting cosmetic and pharmaceutical ingredientscommonly used in the skin care industry, which are suitable for use inthe articles of the present invention. Examples of these ingredientclasses include: enzymes, absorbents, aesthetic components such asfragrances, pigments, colorings/colorants, essential oils, skinsensates, anti-acne agents (e.g., resorcinol, sulfur, salicylic acid,erythromycin, zinc, etc.), anti-caking agents, antifoaming agents,additional antimicrobial agents (e.g., quaternium-15, methyl paraben,ethyl paraben, propyl paraben, DMDM hydantoin etc.), antioxidants,binders, biological additives, buffering agents, bulking agents,chelating agents, chemical additives, colorants, cosmetic biocides,denaturants, external analgesics, film formers or materials, e.g.,polymers, for aiding the film-forming properties and substantivity ofthe composition (e.g., copolymer of eicosene and vinyl pyrrolidone),humectants, opacifying agents, pH adjusters, propellants, reducingagents, sequestrants, skin-conditioning agents (humectants, includingmiscellaneous and occlusive), skin soothing and/or healing agents (e.g.,panthenol and derivatives (e.g., ethyl panthenol), aloe vera,pantothenic acid and its derivatives, allantoin, bisabolol, anddipotassium glycyrrhizinate), skin treating agents, thickeners,hydrocolloids, particular zeolites, and vitamins and derivatives thereof(e.g., tocopherol, tocopherol acetate, beta carotene, retinoic acid,retinol, retinoids, retinyl palmitate, niacin, niacinamide, and thelike). The cleansing compositions and/or articles of the presentinvention may include carrier components such as are known in the art.Such carriers can include one or more compatible liquid or solid fillerdiluents or vehicles which are suitable for application to skin or hair.Typically, such material comprise from about 0.01% to about 40%, byweight, of the compositions herein.

The cleansing compositions and/or articles of the present invention mayoptionally contain one or more of such optional components.

The optional components useful herein can be categorized by theirtherapeutic or aesthetic benefit or their postulated mode of action.However, it is to be understood that the optional components usefulherein can in some instances provide more than one therapeutic oraesthetic benefit or operate via more than one mode of action.Therefore, classifications herein are made for the sake of convenienceand are not intended to limit the component to that particularapplication or applications listed. Also, when applicable, thepharmaceutically-acceptable salts of the components are useful herein.

Chelators

The articles of the present invention may also comprise a safe andeffective amount of a chelator or chelating agent. As used herein,“chelator” or “chelating agent” means an active agent capable ofremoving a metal ion from a system by forming a complex so that themetal ion cannot readily participate in or catalyze chemical reactions.The inclusion of a chelating agent is especially useful for providingprotection against UV radiation that can contribute to excessive scalingor skin texture changes and against other environmental agents, whichcan cause skin damage. Typically, such materials can comprise from about0.01% to about 40%, by weight, of the compositions herein.

A safe and effective amount of a chelating agent may be added to thecompositions of the subject invention, preferably from about 0.1% toabout 10%, more preferably from about 1% to about 5%, of thecomposition. Exemplary chelators that are useful herein are disclosed inU.S. Pat. No. 5,487,884, issued Jan. 30, 1996 to Bissett et al.;International Publication No. 91/16035, Bush et al., published Oct. 31,1995; and International Publication No. 91/16034, Bush et al., publishedOct. 31, 1995. Preferred chelators useful in compositions of the subjectinvention are furildioxime and derivatives thereof.

Binders

The articles of the present invention may optionally comprise binders.Binders or binding materials are useful for sealing the various layersof the present articles to one another thereby maintaining the integrityof the article. The binders may be in a variety of forms including, butnot limited to, spray on, webs, separate layers, binding fibers, etc.Suitable binders may comprise latexes, polyamides, polyesters,polyolefins and combinations thereof. Typically, such materials comprisefrom about 0.01% to 40% of the compositions herein.

E. Properties of Article Components

The articles of the present invention exhibit specific physicalproperties as defined by the both the Dynamic and Flow ViscosityMeasurement, Eye Sting Test, Abrasiveness Value Test, Foamability Testand the Moisture Retention Value Methodology. These methods aredescribed below.

Dynamic Viscosity Measurement

Dynamic viscosity of the compositions is measured using a viscometer(available from TA Instruments of New Castle, Del. as model numberAR-1000N) in an oscillation mode. The measurements are conducted using aparallel plate measuring system, having a diameter of 40 mm and a gap of600 micron. The measurement commences after about 180 secondsequilibration time. Measurements are conducted on a temperature sweepfrom about 20° C. to 80° C. The dynamic viscosity measured at 2.498 Hzfrequency and 0.50 Pa oscillatory stress is used to characterize thecompositions. That is, all the dynamic viscosities disclosed and/orclaimed herein are measured at the operating conditions given above.

Flow Viscosity Measurement

The flow properties of the composition are measured using a viscometer(available from.TA Instruments of New Castle, Del. as model numberAR-1000N) in a flow mode. The measurements are conducted using aparallel plate measuring system, having a diameter of 40 mm and a gap of600 micron. The measurement commences after about 180 secondsequilibration time. Viscosity measurements are conducted on a continuousshear ramp at both 25° C. and 60° C. with a shear rate of 10 inverseseconds (1/s).

Eye Sting Test

Twenty (20) panelists are given four (4) articles comprising thecleansing composition of Example 1 (below) deposited onto a waterinsoluble substrate. They are instructed to wash their faces with eachof the articles using the lathered article directly on or near the eyearea. They are then asked to fill out a questionnaire detailing how theyused the articles and if there was any irritation (eye or skin) causedby the article.

Abrasiveness Value Methodology

The Abrasiveness Value indicates the “non-scouring” property of thewater insoluble substrate layers of the present articles. The layers ofthe present invention can be mildly exfoliating but are not rough (i.e.,are soft) to the skin. Therefore, the Abrasiveness Value determinationinvolves rubbing the substrate along a test surface using a mechanicaldevice and then examining the resulting scratch marks produced on thetest surface using different analysis techniques.

The following equipment is needed for the methodology.

-   1. Martindale Toothbrush Wear and Abrasion Tester: Model 103, serial    nos. 103-1386/2 upwards. Martindale 07-01-88 made by James H. Heal    and Co. Ltd. Textile Testing and QC Equipment. Foot area: 43×44 mm.    1 Kg weight.-   2. Capped Polystyrene strips 11×8 cm. Clear general purpose    polystyrene layer on white High Impact Polystyrene e.g. EMA Model    Supplies SS-20201L.-   3. Substrates to be tested.-   4. Glossmeter e.g. Sheen Tri-Microgloss 20-60-85    Prepare the polystyrene strips for scratching by removing plastic    protective coating from the side to be scratched and rinsing with    ethanol (do not use tissue). Place the strip onto non abrasive    surface and allow strip to dry in the air. Then, attach the    polystyrene strip to the base of a Martindale wear tester with tape    along the edges. Align the strip centrally under the path of the    scrubbing device, with the length of the strip in the direction of    movement. Cut a 2.5″×2.5″ substrate sample. Attach the substrate    sample to the scrubbing foot of the Martindale wear tester, with    double sided tape, aligning the machine direction of the substrate    with the direction of travel. Secure the scrubbing foot assembly    into the instrument with the screws supplied. Slot 1 Kg weight on to    the top of the scrubbing foot assembly and ensure the scrubbing foot    moves only in one direction (forward and backwards). Cover the    entire Martindale wear tester with a safety screen. Set the machine    to perform 50 cycles in 1 minute and allow to run. (Frequency=0.833    Hz).

Once the machine has stopped take off the footer assembly and lift thepolystyrene strip off the base of the machine. Label the polystyreneindicating the substrate used and store in a plastic bag.

Next, the strips are analyzed. The strips are placed on a blackconstruction paper background and at least 5 samples of the samesubstrate are analyzed to get a reproducible average. The Glossmeter isplaced orthogonally (such that light beam is at right angles toscratches) and centrally over the scratched side of the polystyrenestrip. A 20° angle is selected and the sample is measured yielding theAbrasiveness Value. As the Abrasiveness Value decreases the scratchinessor scouring property of a substrate increases.

Moisture Retention Value Methodology

As described above, the articles of the present invention are consideredto be “substantially dry”. As used herein, “substantially dry” meansthat the articles of the present invention exhibit a Moisture RetentionValue of less than about 0.95 gms, preferably less than about 0.75 gms,even more preferably, less than about 0.5 gms, even more preferably lessthan about 0.25 gms, even still more preferably less than about 0.15gms, and most preferably, less than about 0.1 gms. The MoistureRetention Value is indicative of the dry feel that users perceive upontouching the articles of the present invention as opposed to the feel of“wet” wipes.

In order to determine the Moisture Retention Value of the presentarticles and other disposable substrate-based products, the followingequipment and materials are needed. Bounty White Paper Towel Procter &Gamble SKU 37000 63037 Basis Weight = 42.14 gsm Balance Accurate to 0.0g Lexan 0.5″ thickness large enough to cover samples completely andweighs 1000 g Weight A 2000 g weight or combination to equal 2000 g

Next, weigh two paper towels separately and record each weight. Placeone paper towel on flat surface (e.g., lab bench). Place the samplearticle on top of that towel. Place the other paper towel on top ofsample article. Next, place the Lexan and then the 2000 g weight(s) ontop of the sandwiched sample article. Wait 1 minute. After the minute,remove weight(s) and Lexan. Weigh the top and bottom paper towel andrecord the weight.

Calculate the Moisture Retention Value by subtracting the initial papertowel weight from the final weight (after 1 minute) for both the top andbottom paper towels. Add the weight differences obtained for the top andbottom paper towels. Assuming multiple articles are tested, average thetotal weight differences to obtain the Moisture Retention Value.

F. Methods of Manufacture

The cleansing articles of the present invention are manufactured byfirst producing the cleansing composition (paste) by addition of thecomponents and mixing. The cleansing composition is then added to theappropriate water insoluble substrate of the first layer via aconventional method which may include, but is not limited to, spraying,slot coating, and roll transfer (e.g., pressure roll). Whereappropriate, the water insoluble substrate of the second layer is thenplaced on the substrate of the first layer over the cleansingcomposition.

When two or more of these substrate layers are bonded together anysuitable means which one having ordinary skill in the art would chooseand be used. Examples are, but are not limited to, heat bonding,ultrasonic bonding, pressure bonding, entangling by water or mechanicalmeans (needling), sewing, gluing (see binders below), etc.

In a preferred embodiment, the bonding sites are created in areas of thearticle where there is no surfactant or benefit agent present at thebond site for optimal bond strength. Suitable bonding patterns are forexample, but are not limited to, bonding in dots, stripes, lines, waves,or even more complex geometries.

G. Methods of Cleansing and Delivering a Therapeutic or AestheticBenefit Agent to the Skin or Hair

The articles of the present invention are intended to be wetted withwater prior to use. The article is wetted by immersion in water or byplacing it under a stream of water. When the articles of the presentinvention comprise a lathering surfactant in the cleansing composition,lather may be generated from the article by mechanically agitatingand/or deforming the article either prior to or during contact of thearticle with the skin or hair. The resulting lather is useful forcleansing the skin or hair. During the cleansing process and subsequentrinsing with water, any therapeutic or aesthetic benefit agents aredeposited onto the skin or hair. Deposition of the therapeutic oraesthetic benefit agents are enhanced by the physical contact of thesubstrate with the skin or hair as well by the inclusion of one or moredeposition aids.

The following examples further illustrate the invention, but are notintended to be limiting thereof. Example I (Cleansing Composition)Component % wt. Sodium Laureth-3 Sulfate 63.6 Cocamidopropyl Betaine23.8 PEG-200 Glyceryl Tallowate 10.0 Polyquaternium-10 1.1 PreservativeSystem 0.5 Whitener 0.5 Perfume 0.5

Results of Eye Sting Testing of articles comprising a water insolublesubstrate and the cleansing composition of Example 1: Five (5) of thetwenty (20) panelists experience some sort of eye irritation. Four (4)of these judged the irritation to be “mild” and the irritation occurredwith only one of the four articles. Three (3) of these five (5)panelists call the irritation nothing more than a “mild sensation” likethat of having water in the eyes. The fifth person experiences moderateirritation, like a particle is lodged in the corner of the eye, andagain this occurs with only one of the four articles. Example II(Cleansing Composition) Component % wt. Sodium Lauryl Sarcosinate 49.4Cocamidopropyl Betaine 28.0 PEG-200 Glyceryl Tallowate 20.0Polyquaternium-10 1.1 Preservative System 0.5 Whitener 0.5 Perfume 0.5

Example III Component % wt. Sodium Laureth-3 Sulfate 43.6 CocamidopropylBetaine 23.8 Sodium Lauroyl EDTA 20.0 PEG-200 Glyceryl Tallowate 10.0Polyquaternium-10 1.1 Preservative System 0.5 Whitener 0.5 Perfume 0.5

EXAMPLE IV

A representative skin cleansing article is prepared in the followingmanner.

The cleansing composition of Example 1 is applied to one side of a firstsubstrate by extruding it through a coating head continuously in fourlines separated by a distance of 20 mm, 40 mm, and 20 mm respectively,measuring widthwise across the sheet, making a pair of parallel lines onthe face of the interior side of the sheet.

The cleansing composition is extruded at a rate to yield 2.0 grams ofcleansing composition per finished article. The substrate sheet is a anairlaid, lofty, low density batting. The batting comprises a blend of30% 15 denier PET fibers, 35% 3 denier bicomponent fibers with PET coreand PE sheath, and 35% 10 denier bicomponent fibers of the samecore-sheath composition, and has a basis weight of about 100 grams persquare meter (gsm). A second sheet which is a spunlace blend of 50%polyethylene and 50% polypropylene fibers and which has a basis weightof about 30 gsm is continuously fed over the first substrate placing itin contact with the surfactant-containing layer. A third sheet which isa spunlace blend of 50% polyethylene and 50% polypropylene fibers andwhich has a basis weight of about 30 gsm is continuously fed below thefirst substrate, thereby, placing it in contact with the bottom of thecleansing composition-containing layer. The sheet are continuously fedto an ultrasonic sealer which seals a dot pattern comprising a grid of 4mm diameter sealing points spaced evenly across the face of the sheet.The sheet is cut into individual articles measuring about 120 mm×160 mmrectangles with rounded corners, which has a total of about 51 sealingpoints per article.

The foregoing discloses various examples and embodiments of theinvention, but other embodiments fall within the scope of the invention,as would be clear to one of skill in the art.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A cleansing composition comprising one or more surfactants selectedfrom the group consisting of: i) anionic surfactants, ii) amphotericsurfactants, iii) nonionic surfactants, iv) cationic surfactants, and v)mixtures thereof; and wherein the dynamic viscosity of the cleansingcomposition in paste form is at least about 100,000 centipoise andwherein the cleansing composition results in no or minimal eye sting. 2.The composition of claim 1 wherein the cleansing composition has a firstdynamic viscosity at 25° C. and a second dynamic viscosity over atemperature range of 60° C. to 125° C., said first and second dynamicviscosities having a ratio of said first dynamic viscosity to saidsecond dynamic viscosity greater than or equal to about 1.1.
 3. Thecomposition of claim 1 wherein the cleansing composition has a firstflow viscosity at 25° C. and a second flow viscosity over a temperaturerange of 60° C. to 125° C., said first and second flow viscositieshaving a ratio of said first flow viscosity to said second flowviscosity greater than or equal to about 1.1.
 4. The composition ofclaim 1 wherein the anionic surfactant is an alkyl ether sulfate.
 5. Thecomposition of claim 4 wherein the alkyl ether sulfate is sodium laurethsulfate
 6. The composition of claim 1 wherein the amphoteric surfactantis a betaine.
 7. The composition of claim 6 wherein the betaine iscocoamidopropyl betaine.
 8. The composition of claim 1 wherein thenonionic surfactant is PEG 200 glyceryl tallowate.
 9. A process forproducing a substantially dry disposable personal care article suitablefor cleansing, said process comprising the steps of: a) providing afirst water insoluble substrate layer, having an interior surface; b)forming a paste containing surface by extruding and distributing ontosaid interior surface a paste comprising a cleansing composition, saidcomposition comprising one or more surfactants selected from the groupconsisting of: i) anionic surfactants, ii) amphoteric surfactants, iii)nonionic surfactants, iv) cationic surfactants, and v) mixtures thereof,and wherein the dynamic viscosity of the cleansing composition in pasteform is at least about 100,000 centipoise and wherein the cleansingcomposition results in no or minimal eye sting.
 10. The processaccording to claim 9 further comprising the step of applying at least asecond additional water insoluble substrate layer to the pastecontaining surface of the first water insoluble substrate layer.
 11. Theprocess of claim 9 wherein the paste is extruded and or distributed inthe form of a pattern.